Improving Coil Coating Efficiency with X-Rite's ERX145 Solutions

The application of coil coating has transformed the traditional method of painting metal sheets; not only has it expediated the process but also delivered superior and enduring results. Nevertheless, the fast-paced nature of production lines introduces challenges, particularly in maintaining uniform color and gloss.

In addressing these challenges, X-Rite's inline color control systems offer practical solutions to monitor and ensure real-time color quality, minimizing the risks of waste and costly rework.

In today’s article, we will examine the challenges within the coil coating process and how X-Rite's solutions can provide valuable assistance.

The Challenges in the Coil Coating Process

Each step within the coil coating process is critical, but the very intricacies of this process can introduce challenges that may impact the desired color quality and consistency.?

• Fluctuations in temperature during production can influence color.
• Paint, powder, and film thickness variations may occur during spray fabrication.
• Oven temperature and curing times can impact both color and adhesion.
• Continuous pass production lines have the potential to generate significant product waste if color shifts are not promptly addressed.

These challenges can result in undesired waste and may require costly rework efforts. Addressing these complexities is crucial to maintaining product quality and avoiding unnecessary costs. Solutions like X-Rite's inline color control systems offer real-time monitoring to help address these challenges in a more efficient coil coating process.

How X-Rites ERX145 Improves Coil Coating Color Control

?X-Rite's ERX145 is a specialized tool designed for non-contact color measurements on coil coating production lines, aiming to prevent color errors, especially in environments with frequent color changes. When used with the ESWin QC software, it functions as an inline quality control system, detecting color shifts and allowing operators to make real-time adjustments.?

Key features include a 45°:0° measurement geometry for early recognition of color shifts. The device can measure color on hot coated surfaces, using a built-in pyrometer to account for temperature variations. The ESWin QC software recalculates color to room temperature for accurate inline measurements.

The ERX145 also has greater stability and accuracy, employing real dual-beam measurement and automatic wavelength calibration. External calibration is required only every four weeks for maximum uptime.

Designed for durability in dusty conditions, the ERX145 takes measurements at a distance of 60mm with a 30mm spot, minimizing variation between inline and laboratory measurements. Overall, the ERX145 aims to enhance color control in coil coating processes, providing a reliable and efficient solution for monitoring and adjusting color during production.

The ERX145 Workflow

In practice, the ERX145 smoothly manages color control in the coil coating process through the following steps:

1. The ERX145 starts by measuring the color standard in the lab at different temperatures. It's set up on a heating table to mimic real-world conditions, ensuring accurate color measurements regardless of temperature variations.
2. The established color standard, along with its allowable tolerance, is shared across the network. This ensures that everyone involved, from production control to the coating line and even clients, has real-time visibility into the color standards.
3. Using network connectivity, the production machine is automatically set up for the new job. This simplifies the process, reducing manual steps and the potential for errors during the setup phase.
4. As production begins, the ERX145 and the GlossFlash 6060, if needed, move on a traversing beam above the production line. This allows for continuous color and gloss evaluation without interrupting the production flow.
5. Color measurements are tracked using the ESWin QC software, and real-time results are shared across the network. If the color tolerance is exceeded, the system notifies the operator, enabling prompt corrections to avoid product wastage.
6. Quality records are maintained throughout the process to ensure compliance with international standards. These records contribute to ongoing process improvement by analyzing trends and identifying areas for refinement.

The Benefits of Inline Coil Coating Color Control

Implementing an inline coil coating color control system offers practical benefits and a quick return on investment (ROI), typically within six months:

• Cost Savings in Coating Materials: The system optimizes color application, reducing the need for excessive primer and powder coating, leading to cost savings.
• Minimized Waste and Rework: Early detection of color issues prevents the production of defective products, reducing waste and minimizing the need for costly rework.
• Timely Issue Identification: Early detection of color discrepancies saves costs by avoiding the production of products that deviate from specifications.
• Improved Visibility and Slight Revenue Boost: Providing visibility to all stakeholders contributes to informed decision-making, potentially leading to a modest revenue increase of around 5% by consistently meeting color specifications and enhancing customer satisfaction.

X-Rite's ERX145 and its innovative solutions effectively address the challenges of the coil coating process, contributing to increased efficiency, cost-effectiveness, and consistent color quality. These advancements are valuable in the evolving landscape of industries, ensuring precision and reliability in line with modern production needs.